Gateway Interface for Solid-State Breaker Load Disconnect
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Solution Overview
Problem
Industrial automation systems face challenges in effectively protecting electrical loads from overvoltage and overcurrent conditions due to limitations in traditional semiconductor devices, which often result in the use of mechanical circuit breakers that can lead to arc flashes and increased operational risks.
Innovation Solution
The development of solid-state circuit breakers utilizing silicon-carbide (SiC) semiconductor devices, which integrate galvanic disconnecting, overload protection, and motor controlling functions into a single component, reducing the need for mechanical switching and enhancing safety by minimizing arc flash occurrences and allowing for more compact designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional semiconductor devices are used in circuit breakers, then the device can perform basic circuit protection, but arc flashes and operational risks increase
Solution Approach 1:
The patent replaces mechanical circuit breaker components with solid-state semiconductor devices (specifically SiC MOSFETs and IGBTs). The solid-state switching devices eliminate mechanical contacts and arcs, using electronic switching instead of mechanical opening/closing of circuit contacts. This substitution directly addresses the arc flash hazard while maintaining circuit protection functionality through electronic overcurrent and overvoltage detection and response mechanisms.
2Reliability
If multiple protection functions are integrated into separate components, then each component can be optimized, but the system complexity and space requirements increase
Solution Approach 1:
The patent integrates multiple protection functions (overcurrent protection, overvoltage protection, galvanic disconnecting, and motor controlling) into a single solid-state circuit breaker unit. The controller coordinates multiple solid-state switching devices to perform all these functions simultaneously, eliminating the need for separate mechanical circuit breakers, disconnect switches, and motor control devices. This consolidation reduces system complexity while maintaining comprehensive protection capabilities.
Solution Approach 2:
The solid-state circuit breaker is designed as a universal device that can perform multiple functions: circuit protection against overcurrent and overvoltage, galvanic disconnecting for safety, and motor controlling for starting and stopping. The controller adapts the switching devices to perform different functions based on system requirements, making the device versatile and reducing the total number of components needed in the system.
3Reliability
If mechanical circuit breakers are used, then the disconnecting function is reliable, but the operational risks and maintenance requirements increase
Solution Approach 1:
The patent replaces mechanical disconnecting mechanisms with solid-state switching devices controlled by electronic control logic. The solid-state switches provide galvanic disconnecting by completely stopping current flow through electronic switching, eliminating mechanical wear and contact degradation issues. The controller ensures reliable disconnection through electronic protection schemes while eliminating the need for manual operation and reducing maintenance requirements associated with mechanical components.
Data Source
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AI summary
A system includes a solid-state circuit breaker coupling between a power supply and an electrical load. The system also includes a gateway interface device communicatively coupled to the solid-state circuit breaker and includes a plurality of communication interfaces. In an embodiment, the gateway interface device includes a controller configured to perform operations including determining a connection status of at least one communication interface of the plurality of communication interfaces and determining a number of devices connected to the at least one communication interface, receive a signal from at least one device of the number of devices. In the embodiment, the operations may also include in response to receiving the signal, instructing the solid-state circuit breaker to disconnect the electrical load from the power supply.